The company claims that the system, which is also capable of inserting a booklet into the lid design, can handle speeds in excess of 220 packs per minute.
Kliklok Woodman was awarded the contract and began the installation of three complete packaging systems, comprising Servo IPTUs (Intelligent Product Transfer Units) that feed the margarine tubs broadside into a specially designed conveyor system that accurately positions the product.
This allows the accurate placement of the booklet into the indented lid of the plastic container.
The booklet feeder, which is servo driven and integrated into the infeed conveyor of the 'Prima' end load cartoner, was a key element of the line's design.
"Kliklok Woodman offered a feed geometry which allows accurate positioning of the leaflet into the tub lid, and this was a key factor in our decision to place the orders with them," said Marc Olthoff, Unilever's project manager.
"Kliklok Woodman were able to demonstrate this to us in the early stages of the project. This gave us a high level of confidence that an area which we perceived to be tricky could easily be accomplished. There was an added incentive if Kliklok Woodman could achieve a specific speed target - and this was readily achieved "
The special five-crease sleeve was optimised with Unilever so that a common profile was available to suit the many countries that sell the highly successful pro.activ product.
Kliklok Woodman's unique rotary feeder erects this special carton and accurately shapes the pack to allow the inner product retaining tab to be folded and formed - this then locks the product in place in the open ended sleeve. The cartoner used was a specially customised version of Kliklok's world renowned Prima, built to Unilever's mechanical and electrical specification.
Special design emphasis was invested to ensure that the equipment suits the various local operating requirements - and to meet Unilever's TPM standards.
"This was a real international project which required a creative technical solution to suit our project objectives - Kliklok Woodman delivered on this," said Oltoff. "This has allowed Unilever Europe to assess their performance as a preferred machinery supplier, and a decision will be made shortly."